System and method for cooking a meat patty

ABSTRACT

One variation of a system for cooking food includes: a griddle module including a lower plate configured to receive a food product and an upper plate arranged over the lower plate and configured to contact the food product; a set of induction stations, each induction station including a lower coil configured to inductively couple to the lower plate when the griddle module is arranged in the induction station and an upper coil configured to inductively couple to the upper plate when the griddle module is arranged in the induction station; a hub configured to support the lower plate and the upper plate between the upper and lower coils of the induction stations and to sequentially position the griddle module through the set of induction stations; and a controller configured to drive the upper and lower coils to heat the food product between the lower plate and the upper plate.

This Application claims the benefit of U.S. Provisional Application No.62/162,798, filed on 17 May 2015, which is incorporated in its entiretyby this reference.

This Application is related to U.S. patent application Ser. No.14/208,149, filed on 13 Mar. 2014, U.S. patent application Ser. No.14/534,038, filed on 5 Nov. 2014, and to U.S. patent application Ser.No. 13/911,637, filed on 6 Jun. 2013, all of which are incorporated intheir entireties by this reference.

TECHNICAL FIELD

This invention relates generally to the field of food preparation andmore specifically to a new and useful system and method for cooking ameat patty in the field of food preparation.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a schematic representation of a system;

FIG. 2 is a schematic representation of one variation of the system;

FIG. 3 is a schematic representation of one variation of the system; and

FIG. 4 is a schematic representation of one variation of the system;

FIG. 5 is a schematic representation of one variation of the system;

FIG. 6 is a schematic representation of one variation of the system;

FIG. 7 is a flowchart representation of a method; and

FIG. 8 is a flowchart representation of one variation of the method.

DESCRIPTION OF THE EMBODIMENTS

The following description of the embodiments of the invention is notintended to limit the invention to these embodiments but rather toenable a person skilled in the art to make and use this invention.

1. System

As shown in FIGS. 1 and 2, a system 100 for cooking a meat pattyincludes: a set of griddle modules 110, each griddle module 110 in theset of griddle modules 110 including a lower plate 111 configured toreceive a meat patty and an upper plate 112 arranged over the lowerplate 111 and configured to contact the meat patty; and a set ofinduction stations 120 including an entry induction station 121 and anexit induction station 123, each induction station in the set ofinduction stations 120 including 1) a lower coil 124 configured toinductively couple to an adjacent lower plate 111 and 2) an upperinduction head 126 including an upper coil 125 configured to inductivelycouple to an adjacent upper plate 112. The system 100 also includes: abase 130 including a barrier, housing lower coils 124 of the set ofinduction stations 120 on a first side of the barrier, and supportingeach upper induction head 126 in alignment with a lower coil 124 of acorresponding induction station offset on a second side of the barrieropposite the first side; and a conveyor system including 1) a hub 140supporting lower plates 111 of the set of griddle modules 110 betweenthe barrier and the upper induction heads 126, the lower plates 111offset from the barrier and 2) a hub actuator arranged within the base130 and sequentially indexing each griddle module 110 in the set ofgriddle modules 110 from the entry induction station 121 to the exitinduction station 123. The system 100 further includes: a retrievalsystem including a paddle and a retrieval actuator, the retrievalactuator selectively advancing the paddle across a lower plate 111 inthe exit induction station 123 to collect a patty from the lower plate111.

As shown in FIGS. 5 and 6, one variation of the system 100 for cooking afood product includes: a first griddle; a second griddle; a set ofinduction stations 120; a base 130; a hub 140; and a controller 180. Inthis variation, the first griddle module 110 includes a lower plate 111configured to receive a first food product and an upper plate 112arranged over the lower plate 111 and configured to contact the firstfood product. The set of induction stations 120 includes an entryinduction station 121 and an exit induction station 123, wherein eachinduction station in the set of induction stations 120 includes a lowercoil 124 configured to inductively couple to the lower plate 111 whenthe first griddle module 110 is arranged in the induction station and anupper coil 125 configured to inductively couple to the upper plate 112when the first griddle module 110 is arranged in the induction station.The base 130 includes a barrier, is configured to support a lower coil124 of an induction station on a first side of the barrier, and isconfigured to support an upper coil 125 of an induction station on asecond side of the barrier opposite and aligned with the lower coil 124of the induction station for each induction station in the set ofinduction stations 120. The hub 140: is configured to support the lowerplate 111 and the upper plate 112 of the first griddle module 110between the barrier and upper coils 125 of the induction stations withthe lower plate 111 offset above the barrier and the upper plate 112offset below upper coils 125 of the induction stations; and isconfigured to sequentially position the first griddle module 110 throughthe set of induction stations 120 from the entry induction station 121to the exit induction station 123. In this variation, the controller 180is configured to drive lower coils 124 and upper coils 125 of the set ofinduction stations 120 based on a position of the first griddle module110 within the set of induction stations 120 to heat the first foodproduct between the lower plate 111 and the second plate.

2. Method

As shown in FIGS. 7 and 8, a method S100 for cooking a meat pattyincludes: elevating an upper induction head at an entry station toseparate a first upper plate from a first lower plate at the entrystation in Block S110; dispensing a meat patty onto the lower plate inBlock S112; at a first time, powering a lower coil at the entry stationto induction heat the first lower plate and powering an upper coil atthe entry station to induction heat the first upper plate in Block S120;disabling the upper and lower coils at the entry station in Block S130;indexing a hub to shift the first lower plate and the first upper plateto an intermediate station and to shift a second lower plate and asecond upper plate to the entry station in Block S140; at a second timesucceeding the first time, powering a lower coil at the intermediatestation to induction heat the first lower plate and powering an uppercoil at the intermediate station to induction heat the first upper platein Block S122; disabling the upper and lower coils at the intermediatestation in Block S132; indexing the hub to shift the first lower plateand the first upper plate to an exit station in Block S142; at a thirdtime succeeding the second time, powering a lower coil at the exitstation to induction heat the first lower plate and powering an uppercoil at the intermediate station to induction heat the first upper platein Block S124; elevating an upper induction head at the exit station toseparate the first upper plate from the first lower plate at the exitstation in Block S160; and removing the meat patty from the first lowerplate at the exit station in Block S162.

One variation of the method 100 includes: separating a first upper plateof a first griddle module from a first lower plate of the first griddlemodule positioned within an entry induction station in Block S110;dispensing a first food product onto the first lower plate in BlockS112; during a first period of time, driving a lower coil in the entryinduction station to heat the first lower plate and driving an uppercoil in the entry induction station to heat the first upper plate inBlock S120; during a second period of time succeeding the first periodof time, disabling the lower coil and the upper coil in the entryinduction station in Block S130; during the second period of time,positioning the first griddle module within an intermediate inductionstation in Block S140; during a third period of time succeeding thesecond period of time, driving a lower coil in the intermediateinduction station to heat the first lower plate and driving an uppercoil in the intermediate induction station to heat the first upper platein Block S122; during a fourth period of time succeeding the thirdperiod of time, disabling the lower coil and the upper coil in theintermediate induction station in Block S132; during the fourth periodof time, positioning the first griddle module within an exit inductionstation in Block S142; during a fifth period of time succeeding thefourth period of time, driving a lower coil in the exit inductionstation to heat the first lower plate and driving an upper coil in theexit induction station to heat the first upper plate in Block S124; at asixth time succeeding the fifth period of time, separating the firstupper plate from the first lower plate of the first griddle modulepositioned within the exit induction station in Block S160; and removingthe first food product from the first lower plate in Block S162.

The foregoing variation of the method 100 can also include: during thethird period of time: separating a second upper plate of a secondgriddle module from a second lower plate of the second griddle modulepositioned within the entry induction station, dispensing a second foodproduct onto the second lower plate, and driving the lower coil in theentry induction station to heat the second lower plate and driving theupper coil in the entry induction station to heat the second upperplate; during the fourth period of time, disabling the lower coil andthe upper coil in the entry induction station; during the fourth periodof time, simultaneously positioning the second griddle module within theintermediate exit induction station; and during the fifth period oftime, driving the lower coil in the intermediate induction station toheat the second lower plate and driving the upper coil in theintermediate induction station to heat the second upper plate.

3. Applications

The system 100 for cooking a food product (e.g., a hamburger patty, asteak) functions to receive a food product between upper and lowerplates of a griddle module, to compress the food product between theupper and lower plates of the griddle module, to sequentially advancethe griddle module through each induction station in a set of inductionstations, and to sequentially power upper and lower induction coils ofeach induction station based on the position of the griddle module toheat the upper and lower plates of the griddle module, thereby heating(e.g., cooking) the food product. The system 100 then removes the foodproduct from the griddle module once the griddle module has entered orpassed through a last induction station.

The system 100 can also include a set of (e.g., five) griddle modules,such as one griddle module for each induction station. For example, thesystem 100 can receive a first food product at a first griddle modulearranged in an entry induction station while a second, a third, and afourth food product are heated between upper and lower plates of second,third, and fourth griddle modules in second, third, and fourth inductionstations, respectively, and while a fifth food product is removed from afifth griddle module in an exit induction station. In this example, oncethe first food product is inserted into the first griddle module andinitially heated in the first induction station, the system 100 candeactivate all coils in all induction stations before indexing thegriddle modules forward in order to position the first griddle module inthe second induction station, to position the second griddle module inthe third induction station, to position the third griddle module in thefourth induction station, to position the fourth griddle module in theexit induction station, and to position the fifth griddle module in theentry induction station. As the second induction station heats the firstfood product between the upper and lower plates of the first griddlemodule, the system wo places a sixth food product into the fifth griddlemodule in the entry induction station and removes the fourth foodproduct from the fourth griddle module in the exit induction station.The system 100 can then repeat this process over time to continuouslyreceive food products at griddle modules in the entry induction station,to sequentially heat (or cook) food products from the entry inductionstation through the exit induction station, and to retrieve heated (orcooked) food products from griddle modules in the exit inductionstation. In this example, the system 100 can receive a sequence ofhamburger patties from a patty grinding system, sequentially inserthamburger patties into griddle modules in the entry induction station,simultaneously cook multiple hamburger patties to various donenesslevels at each induction station, and remove done hamburger patties fromgriddle modules at the exit induction station.

As a griddle module containing a food product is indexed from the entryinduction station through to the exit induction station, as shown inFIG. 7, the system 100 can also modulate a power output at eachinduction station in order to achieve a target doneness for the foodproduct. For example, when the griddle module in the entry inductionstation receives a hamburger patty assigned a medium doneness level, thesystem 100 can implement closed-loop feedback techniques to modulate thepower outputs of the upper and lower coils in the entry inductionstation based on outputs of temperature sensors thermally coupled to theupper and lower plates in the griddle module in order to maintain atarget entry stage temperature for a medium doneness level. In thisexample, once the griddle module is indexed to a second inductionstation, the system 100 can again implement closed-loop feedbacktechniques to modulate the power outputs of the upper and lower coils ina second induction station based on outputs of temperature sensorsthermally coupled to the upper and lower plates in the griddle module inorder to maintain a target second stage temperature for a mediumdoneness level. In this example, the system 100 can repeat this processuntil the hamburger patty is fully cooked to a medium doneness level atthe exit induction.

Furthermore, the system 100 can actively control compression of a foodproduct between the upper and lower plates of a griddle module in orderto achieve a doneness level assigned to the food product. For example,the system 100 can include a compression actuator 128 configured todrive the upper and lower plates of a griddle module together toincrease the cook rate of a hamburger patty arranged in the griddlemodule, thereby yielding a hamburger patty of a greater doneness levelupon completion of a cook cycle. The system 100 can similarly controlthe compression actuator 128 to separate the upper and lower plates of agriddle module in order to decrease the cook rate of a hamburger pattyarranged in the griddle module, thereby yielding a hamburger patty of alesser doneness level upon completion of a cook cycle. Alternatively,the system 100 can actively adjust a stop in a griddle module in orderto set a minimum offset distance between the bottom face of an upperplate and the top face of a corresponding lower plate of a griddlemodule based on a doneness level assigned to a food product. The system100 can thus control one or more cook parameters, such as temperatureand compression, to cook a food product—within a griddle module—to atarget doneness or to a target temperature independent of other foodproducts cooking in other griddle modules in the system 100.

Upon completion of a cook cycle at a griddle module (i.e., uponadvancement of the griddle module from the entry induction stationthrough to the exit induction station), the system 100 can then remove aheated or cooked food product from the griddle module. For example, forthe food product that includes a hamburger patty, the system 100 canremove the hamburger patty from a griddle module in the exit inductionstation and dispense the hamburger patty onto a hamburger bun nearby inpreparation for delivering a completed hamburger to a patron accordingto a custom hamburger order recently submitted by the patron.

The system 100 is described herein as a system for cooking raw hamburgerpatties. However, the system 100 can additionally or alternatively cookor heat: vegetable patties; raw patties of ground fish, poultry, pork,lamb, or bison, etc.; raw beef, fish, bison, or lamb, etc. steaks; rawchicken breasts; cooked or uncooked sausage; and/or any other raw,semi-cooked, or cooked food product of any other geometry and candispense such a food product onto any other cooking surface, heatingsurface, hamburger bun, bread slice, bed of greens, plate, bowl, orother container or surface upon completion of a cook cycle.

4. Automated Food Assembly Apparatus

The system 100 can function as a subsystem within an automated foodstuffassembly apparatus 200 including one or more other subsystems thatautomatically prepare, assemble, and deliver foodstuffs according tocustom food orders submitted by local and/or remote patrons. Forexample, the automated foodstuff assembly apparatus 200 can include: abun dispenser and slicing subsystem that slices and dispenses a bun froma bun hopper; a bun buttering subsystem that applies butter to each sideof the sliced bun prior to toasting the halves of the bun; a bun toastersubsystem that toasts each side of the bun; a topping module that loadsa custom set of toppings in custom quantities onto the bun heelaccording to topping specifications in a custom food order received froma patron; a condiment subsystem that loads condiments onto the bun crownaccording to condiment specifications in the custom food order; a pattygrinding system that grinds a quantity of raw meat (e.g., based on acustom patty size and a custom meat blend specified in the custom foodorder) and that presses this quantity of meat into a custom hamburgerpatty (e.g., to a compression level corresponding to a custom donenesslevel specified in the custom food order); the system 100 functioning asa patty cooking subsystem that cooks the hamburger patty received fromthe patty grinding system according to the custom doneness levelspecified in the custom food order and dispenses the cooked hamburgerpatty onto the bun heel; and a boxing subsystem that closes thecompleted hamburger within a paper box for subsequent delivery to thecorresponding patron.

The system 100 can cook hamburger patties or veggie patties (e.g., fromraw or cooked vegetables) for assembly into other types of assembledfoodstuffs, such as sandwiches, hotdogs, burritos, tacos, salads, orwraps, etc. according to custom food orders submitted by patrons to arestaurant, food truck, convenience store, grocery store, or food kiosk,etc. housing an automated foodstuff assembly apparatus. The system 100can therefore be incorporated into an automated foodstuff assemblyapparatus 200 to automatically cook whole or ground meat or vegetableproducts once an order for a hamburger (or other foodstuff) is submittedby a patron and while other components of the patron's order areprocessed at the automated foodstuff assembly apparatus.

5. Cook Cycle

The system executes the method 100 during a cook cycle to receive asequence of food products (e.g., hamburger patties) and to move eachfood product through the set of induction stations to simultaneously butindependently cook each food product before releasing a food product,such as onto a corresponding hamburger bun or into a box.

Block S110 of the method 100 recites separating a first upper plate of afirst griddle module from a first lower plate of the first griddlemodule positioned within an entry induction station. Generally, in BlockS110, the system 100 separates an upper plate from a lower plate of afirst griddle module in the entry induction station in preparation toload the first griddle module with a food product. In oneimplementation, the entry induction station includes an upper inductionhead that houses the upper coil of the entry induction station and anentry elevation actuator 127 configured to (linearly or arcuately) liftthe upper induction head of the entry induction station away from thebase. For example, the upper induction head in the entry inductionstation can run vertically on a set of linear rails, and the entryelevation actuator can include a linear actuator oriented verticallybetween the base and the upper induction head and configured to drivethe upper induction head vertically along linear rails. In thisimplementation, a first receiver coupled to the hub and supporting theupper plate of the first griddle module includes a skid 116 thatcontacts the upper induction head (or vice versa) such that the firstreceiver and upper plate rise with the upper induction head when theentry elevation actuator lifts the entry induction head, therebyseparating the upper plate of the first griddle module from itscorresponding lower plate in preparation to receive a food product inBlock no. Alternatively, the system 100 can include an entry elevationactuator at the entry induction station that engages the upper plate ofthe first griddle module directly (or that engages the first receiver ofthe hub directly) to lift the upper plate away from the lower plate ofthe first griddle module. Yet alternatively, the system 100 can includeone entry elevation actuator per griddle module and mounted to the hubbetween the hub and the upper plate of a corresponding griddle module.However, the system 100 can include any other one or more actuators,linkages, etc. configured to elevate the upper induction head in theentry induction station and/or the upper plate of the first griddlemodule positioned in the entry induction station in any other way.

Block S112 of the method 100 recites dispensing a first food productonto the first lower plate in Block S112. Generally, the system 100executes Block S112 once the upper and lower plates of the first griddlemodule in the entry induction station are opened to receive the foodproduct in Block S110. In one implementation, an adjacent patty grindingsystem extends a patty dispenser—with hamburger patty—between the upperand lower plates of the first griddle module and releases the hamburgerpatty onto the lower plate. The system 100 then lowers the upper plateof the first griddle module, such as by lowering the upper inductionhead in the entry induction station, to bring the upper plate in contactwith the hamburger patty.

Block S120 of the method 100 recites, during a first period of time,driving a lower coil in the entry induction station to heat the firstlower plate and driving an upper coil in the entry induction station toheat the first upper plate. Generally, in Block S120, the system 100begins to heat (e.g., cook) the first food product now positionedbetween the upper and lower plates of the first griddle module bysupplying power to the upper and lower coils in the entry inductionstation. In particular, when powered, the upper and lower coils of theentry induction station inductively couple with the upper and lowerplates of the first griddle module, respectively, thereby inducing eddycurrents and heating the upper and lower plates, which conduct heat intothe top and bottom of the food product, respectively.

During a second period of time succeeding the first period of time, thesystem 100: disables the lower coil and the upper coil in the entryinduction station in Block S130; and positions the first griddle modulewithin an intermediate induction station in Block S140. Generally, thesystem 100 disables the upper and lower coils in the entry inductionstation in Block S130 in preparation to advance the first griddle moduleto a next induction station in Block S140. In particular, to preventinductive coupling between the upper and lower coils of the entryinduction station, which may damage the upper and lower coils, when thefirst griddle module is transitioned out of the entry induction station,the system 100 disables (e.g., deactivates, cuts power to) the upper andlower coils in Block S130 before advancing the first griddle module to anext induction station. For example, the system 100 can initiate a timerfor a static intra-station period (e.g., ten seconds) once the firstgriddle module enters the first induction station and then deactivatethe upper and lower coils of the entry induction station in Block S130upon expiration of the timer before advancing the first griddle moduleinto a next induction station.

Block S122 of the method 100 recites, during a third period of timesucceeding the first period of time, driving a lower coil in theintermediate induction station to heat the first lower plate and drivingan upper coil in the intermediate induction station to heat the firstupper plate. Generally, in Block S122, the system 100 implements methodsand techniques like Block S120 described above to power the upper andlower coils of a second induction station (e.g., an intermediateinduction station), which inductively couple to the upper and lowerplates of the first griddle module, respectively, to heat the first foodproduct.

Furthermore, the system 100 can include a hub that supports both a firstgriddle module and a second griddle module behind (i.e., lagging,succeeding) the first griddle module such that, when the system 100advances the first griddle module forward from the entry inductionstation to the second induction station, the second griddle module issimultaneously advanced from the exit induction station to the entryinduction station. Thus, during the third period of time in which thesystem 100 powers the upper and lower coils in the second inductionstation to heat the first food product in the first griddle module inBlock S122, the system 100 can repeat Block S110 to separate the upperplate from the lower plate in the second griddle module and can repeatBlock S112 to dispense a second food product (e.g., a second hamburgerpatty) onto the lower plate of the second griddle module. The system 100can then lower the upper plate of the second griddle module onto thesecond food product and simultaneously supply power to both the upperand lower coils of the second induction station and the upper and lowercoils of the entry induction station, thereby heating the upper andlower plates of the first and second griddle modules, respectively,during the remainder of the third period of time.

For example, the system 100 can power the upper and lower coils of thesecond induction station for a full intra-station period of ten secondsin Block S122 while simultaneously opening the upper and lower plates ofthe second griddle module, loading a second food product into the secondgriddle module, and closing the second griddle module for a subset ofthe intra-station period (e.g., five seconds) in Blocks S110 and S112and then powering the upper and lower coils of the first inductionstation for the remainder of the intra-station period in Block S120. Inthis example, upon expiration of the intra-station period, the system100 can deactivate the upper and lower coils in the second and firstinduction stations in Block S132 and simultaneously advance the firstgriddle module to a third induction station (e.g., to the exit inductionstation), the second griddle module to the second induction station, anda third griddle module to the entry induction station. The system 100can then repeat Blocks S110 and S112 to load a third food product intothe third griddle module while simultaneously powering the upper andlower coils in the third and second induction stations to heat the firstfood product in the first griddle module and to heat the second foodproduct in the second griddle module, respectively, during a secondintra-station period. The system 100 can repeat the foregoing methodsand techniques to load a food product onto a griddle module as eachgriddle module enters the entry induction station, to advance eachgriddle module through the set of induction stations to the exitinduction station, and to intermittently power the upper and lower coilsof the induction stations to heat food products arranged in adjacentgriddle modules.

Block S160 of the method 100 recites, at a sixth time succeeding thefifth period of time, separating the first upper plate from the firstlower plate of the first griddle module positioned within the exitinduction station; and Block S162 of the method 100 recites removing thefirst food product from the first lower plate. Generally, in Blocks S160and S162, the system 100 implements methods and techniques similar tothose of Blocks S110 and S112 to open the first griddle module—nowpositioned in the exit induction station—and to remove the first foodproduct—now fully heated or cooked—from the first griddle module. In oneimplementation, the exit induction station includes an upper inductionhead configured to house the upper coil, the system 100 includes an exitelevation actuator—like the entry elevation actuator—configured toelevate the upper induction head of the exit induction station, and thefirst griddle module includes a skid 116 that engages a feature on theupper induction head of the exit induction station to vertically couplethe first griddle to the upper induction head when the first griddlemodule is positioned in the exit induction station. The system 100 canalso include a retrieval system configured to remove a food product froma griddle module, such as in the form of a paddle and a retrievalactuator that draws the paddle across the lower plate of a griddlemodule positioned in the exit induction station to collect a foodproduct from the griddle module, as described below.

For example, once the first griddle module is positioned in the exitinduction station and once the first food product has reached asufficient temperature, has been exposed to sufficient heat flux, hascooked for a target period of time, or has cooked for at least athreshold period of time through the set of induction stations, thesystem 100 can: deactivate the upper and lower coils in the exitinduction station; trigger the exit elevation actuator to raise theupper induction head of the exit induction station, thereby raising theupper plate of the first griddle module; and then trigger the retrievalactuator to insert the paddle between the first food product and thelower plate. The retrieval actuator can then retract the paddle from thefirst griddle module and draw the paddle across a ledge—arranged over adispense position—to release the first food product from the paddle ontoa hamburger bun (or into a box, onto a salad, etc.) below in Block S162.The system 100 can repeat this process for each griddle module thatenters the exit induction station.

6. Griddle Module and Hub

As shown in FIGS. 1 and 4, the system 100 includes a first griddlemodule 110, which includes a lower plate 111 configured to receive afirst food product and an upper plate 112 arranged over the lower plate111 and configured to contact the first food product. Generally, thesystem 100 includes one or more like griddle modules 110, wherein eachgriddle module 110 includes an upper plate 112 and a lower plate 111configured to inductively couple to upper and lower induction coils,respectively, in an adjacent induction station. When the upper coil ofan induction station outputs an alternating magnetic field thatpenetrates the upper plate 112 of an adjacent griddle module 110 (i.e.,a griddle module 110 arranged in the induction station), eddy currentsform in the upper plate 112, which heat the plate via Joule heating;when similarly powered, the lower coil in the induction station cansimilarly induce eddy currents in the lower plate 111 of the griddlemodule 110 to heat the lower plate 111. When positioned within aninduction station and thus heated via induction heating, a griddlemodule 110 can thus form a double-sided (or “clamshell”) inductivegriddle configured to heat both the top and bottom surfaces of a foodproduct.

In one implementation, the upper plate 112 of a griddle module 110includes a ferrous (e.g., a steel, a cast iron, ferromagnetic, and/orferrimagnetic) substrate defining a planar cooking surface coated with a“non-stick” (e.g., low-friction) material, such as a ceramic (e.g.,alumina), Polytetrafluoroethylene (PTFE), or perfluorooctanoic acid(PFOA). The upper plate 112 can also include one or more thermal layersbetween the ferrous substrate and the non-stick coating. For example,the upper plate 112 can include: a ferrous substrate configured to Jouleheat in the presence of an oscillating magnetic field output by an uppercoil of an adjacent induction station; a copper layer bonded (e.g.,brazed, diffusion bonded) over the ferrous substrate and configured todistribute heat across the ferrous substrate; an aluminum layer bondedover the copper layer to define a planar food-safe cook surface; and anon-stick coating applied over the aluminum layer.

In the foregoing implementation, the upper plate 112 can be symmetricabout its Y-axis and can define a second planar cooking surface oppositeand parallel to the (first) planar cooking surface, wherein the secondcooking surface is similarly coated with a non-stick material. Thus,when the non-stick coating on the first cook surface is sufficientlyworn, the upper plate 112 can be flipped on the hub—such as manually byan operator following a cleaning cycle—to expose the “fresh” non-stickcoating on the second cooking surface. Similarly, the upper plate 112can be systematically flipped about its Y-axis between operating periodsof the automated foodstuff assembly apparatus 200 in order to yieldsubstantially uniform wear of the non-stick coating over time and toextend the useful life of the upper plate 112. In the example above inwhich the upper plate 112 includes one or more thermal layers over aferrous substrate, the upper plate 112 can similarly include copper andaluminum layers across the opposite side of the ferrous substrate suchthat the ferrous substrate defines a ferrous core that heats in thepresence of an oscillating magnetic field, and the copper layers candisperse this heat across both sides of the ferrous core.

A griddle module 110 in the system 100 can include a lower plate 111 ofthe same or similar material(s) and geometry. For example, a griddlemodule 110 can include identical (e.g., interchangeable) upper and lowerplates 112, 111.

The system 100 also includes a hub: configured to support the lowerplate 111 and the upper plate 112 of the first griddle module 110between the barrier and upper coils of the induction stations with thelower plate 111 offset above the barrier and the upper plate 112 offsetbelow upper coils of the induction stations; and configured tosequentially position the first griddle module 110 through the set ofinduction stations from the entry induction station to the exitinduction station 123. Generally, the hub function to support the upperand lower plates 112, 111 of one or more griddle modules 110 betweenupper and lower induction coils of the induction stations throughoutoperation of the system 100.

In one implementation, the upper plate 112 includes an upper platereceptacle 113 configured to locate the upper plate 112 on the hubbetween the upper and lower induction coils of the induction stations,as shown in FIGS. 3 and 5. In one implementation, an upper platereceptacle 113 defines a pair of beams extending outwardly from the hub,and a corresponding upper plate 112 defines a circular cast iron platterof uniform thickness fastened to the beams of the upper plate receptacle113 with one or more threaded fasteners.

In another implementation, the upper plate 112 defines a circular platewith a tongue 117 extending from an edge of the upper plate 112. In thisimplementation, the distal end of the tongue defines a chamfered lead-inon each broad side and a recess behind each chamfered lead-in, as shownin FIG. 3. The upper plate receptacle 113 defines a receiver 116 thataccepts the tongue of the upper plate 112 and a sprung follower 118 thatengages the recess on the tongue of the upper plate 112 to constrain theupper plate 112 in the receiver. In this implementation, to install anupper plate 112 in an upper plate receptacle 113, an operator canmanually insert the tongue of the upper plate 112 into the receiver; thechamfered lead-in of the tongue can retract the follower as the tongueis inserted into the receiver; and the follower can extend into andengage the recess in the tongue to constrain the upper plate 112 in thereceiver once the upper plate 112 is fully inserted into the receiver,thereby locking the upper plate 112 to the upper plate receptacle 113.The operator can then manually draw the upper plate 112 laterally awayfrom the upper plate receptacle 113 to release the follower from therecess and to remove the upper plate 112 from the upper plate receptacle113, such as to clean the system 100. (Alternatively, the upper platereceptacle 113 can include a pin, magnet, or other element or featurethat engages and retains the upper plate.) The upper plate receptacle113 can also include one or more guide rails that laterally constrainthe upper plate.

In one implementation, the system 100 includes: a conveyor systemincluding the hub and a hub actuator 141 that rotates the hub through asequence of positions corresponding to induction stations; and a set oflike griddle modules 110, wherein the upper plate receptacle 113 of eachgriddle module 110 is configured to transiently install on the hub. Forexample, the hub can include a set of vertical posts 143, and each upperplate receptacle 113 can include a linear slide configured to engage andto translate linearly along a corresponding post 143 when lifted by anupper induction head 126 in the entry and exit induction stations 121,123 in Blocks S110 and S160 (or vice versa), as shown in FIGS. 5 and 7.In this example, the hub can include a lower plate 111 receptacleconfigured to transiently receive the lower plate 111, like the upperplate receptacle 113, but intransiently coupled to the hub, and theupper plate receptacle 113 can be configured to slide vertically along apost 143 of the hub to enable the system 100 to separate the upper plate112 from the lower plate 111 in Blocks S110 and S160 in preparation toreceive and to release a food product, respectively. An upper platereceptacle 113 and upper plate 112 assembly can thus be fully removablefrom the post 143 by manually drawing the upper plate receptacle 113vertically upward past the post 143, and the upper plate 112 can beseparated from the lower plate 111 receptacle by drawing the lower plate111 laterally outward, as described above, such as for cleaning.Alternatively, a griddle module 110 can similarly include a lower plate111 receptacle: that transiently engages the hub, such as over a post143 extending from the hub and shared with a corresponding upper platereceptacle 113; that supports the lower plate 111; and that can beremoved from the hub with the upper plate receptacle 113, such as forcleaning or other servicing.

In the foregoing implementation in which the hub includes one verticalpost 143 (or multiple vertical posts) per griddle module 110 and inwhich a griddle module 110 is configured to slide vertically along itscorresponding post 143 on the hub, an upper plate receptacle 113 in agriddle module 110 can further include a skid 116 configured to engagean upper induction head 126 of an adjacent induction station (i.e., theentry induction station, the exit induction station 123) and to loft theupper plate receptacle 113 along its post 143 when the upper inductionhead 126 is retracted, thereby separating the upper plate 112 from itspaired lower plate 111 to receive a new food product at the entryinduction station in Blocks S110 and S112 or to release a cooked foodproduct from the griddle module 110 at the exit induction station 123 inBlocks S160 and S162. For example, the entry induction station caninclude an upper induction head 126 that defines a T-slot concentricwith the axis of rotation of the hub, and a griddle module 110 caninclude a skid 116 defining a T-head configured to enter the T-slot asthe griddle module 110 is advanced into the entry induction station; theupper induction head 126 can thus draw the T-head and the upper platereceptacle 113 upward when elevated by the elevation module in the entryinduction station in Block S110. The exit induction can define a similargeometry configured to elevate the griddle module 110 in Block S160.

The hub can thus support and locate each lower plate 111 of a griddlemodule 110 in vertical alignment with its corresponding upper plate 112and offset vertically above the barrier of the base. In particular, thehub can support lower plates in of the griddle modules 110 out ofmechanical contact with the barrier of the base in order to limitconduction of heat from the lower plates 111 into the barrier and intothe lower coils. For example, the hub can support lower plates 111 ofthe griddle modules 110 at a fixed distance above the barrier and offsetabove lower coils arranged in the base by a distance corresponding to apeak inductive coupling distance for the lower coils.

7. Induction Stations

As shown in FIGS. 1 and 4, an induction station in the system includes aset of induction stations 120 including an entry induction station 121and an exit induction station 123, wherein each induction station in theset of induction stations 120 includes: a lower coil configured toinductively couple to the lower plate when the first griddle module isarranged in the induction station; and an upper coil configured toinductively couple to the upper plate when the first griddle module isarranged in the induction station. Generally, an induction station inthe system 100 includes an upper coil and a lower coil that inductivelycouple to adjacent upper and lower plates of a griddle module,respectively, when the griddle module is positioned within the inductionstation.

In one implementation, each induction station can also include one powercontroller and an electronic oscillator that cooperate to pass ahigh-frequency alternating current through one or both of the upper andlower coils. When thus powered, the upper coil of the induction stationcan output a high-frequency alternating magnetic field that penetratesthe upper plate in an adjacent griddle module, which thus induces eddycurrents in the upper plate. These eddy currents thus formed in theupper plate can then induce heating within the plate, such as by Jouleheating and/or by magnetic hysteresis losses. For example, the system100 can include one power controller and one electronic oscillator pereach of the upper and lower coils in an induction station, one powercontroller and one electronic oscillator per pair of upper and lowercoils in an induction station, or any other number or combination ofpower controllers and electronic oscillators.

An induction station can also include an upper induction head 126 thathouses the upper coil of the induction station, as described above. Inone implementation, an upper induction head 126 can include a housinghinged to and supported by the base and defining an aperture facing thebase. The upper coil of the induction station can be arranged within thehousing and can be configured to output an alternating magnetic fieldthrough the aperture. Furthermore, the aperture can be closed by awindow of a substantially magnetically-transparent material (e.g.,window of a material exhibiting relatively minimal ferromagnetism andrelatively minimal ferrimagnetism) that physically seals the upper coilwithin the housing. For example, the window can include a borosilicatetransparent glass plate exhibiting a relatively low coefficient ofthermal expansion and supported by a flexure extending from the housing.The upper induction head 126 can also include a heat barrier between theupper coil and the non-magnetic window to reduce heat transmission fromoutside the housing into the upper coil, and the upper induction head126 can be coupled to a remote air supply that forces air through theupper induction head 126 to actively cool the upper coil.

The upper coil of the entry induction station 121 can be housed in adiscrete entry upper induction head 126, and the upper coil of the exitinduction station 123 can be similarly housed in a discrete exit upperinduction head 126. Upper coils in two or more intermediate inductionstations 122 can be ganged into a single housing to form a single upperinduction head 126 that spans the multiple intermediate inductionstations 122, as shown in FIG. 2. For example, the induction station caninclude a single housing containing three upper coils for each of threeintermediate induction stations 122. Furthermore, the system 100 cansupport the ganged upper induction head 126 in a static position offsetabove the base and spanning the intermediate induction stations 122.

Furthermore, the upper induction head 126 of the entry induction station121 can be coupled to an elevation actuator 127 configured to raise andlower the upper entry induction head to thus raise and lower the upperplate of a griddle module in entry induction station 121 in Block S110;the upper induction head 126 of the exit induction station 123 can besimilarly coupled to an elevation actuator 127 configured to raise andlower the upper induction head 126 in Block S160. For example, an upperinduction head 126 can be supported over the base by a pair of parallellinkages coupled to a linear or rotatory actuator, as shown in FIG. 1,configured to lift the induction head (and an adjacent upper plate) by arelatively small distance (e.g., 2.0″) to accept a new food product inBlocks S110 and S112 or to release a cooked food product in Blocks S160and S162. Alternatively, like the upper plate receptacle and hub, anupper induction head 126 can slide vertically along a post 143 extendingfrom the base, and a linear actuator, rotatory actuator, and/or linkagesystem can position the upper induction head 126 along the post 143 inorder to separate the upper plate from the lower plate of an adjacentgriddle module in Block S110 or Block S160 and/or to set an offsetdistance or compression height between the upper and lower plates in theadjacent griddle module in Block S182 described below. Individual organged upper induction heads 126 in the intermediate inductionstation(s) 122 can be similarly supported off of the base and can besimilarly adjusted vertically to set offset distances or compressionheights between the upper and lower plates in adjacent griddle modulesin Block S182.

The lower induction coil can be arranged in the base, as describedbelow.

In one implementation, the system 100 includes a number of inductionstations equal to its number of griddle modules. In this implementation,the system 100 can load raw food products into griddle modules in theentry induction station 121 in Block S112 and remove cooked foodproducts from griddle modules in the exit induction station 123 in BlockS162. For example, the system 100 can include an entry induction station121, three intermediate induction stations 122, and one exit inductionstation 123. Alternatively, the system 100 can include one fewerinduction station than griddle modules. For example, the system 100 canremove a cooked food product and then reload the griddle module with araw food product in Blocks S162 and S112, respectively, when the griddlemodule is positioned in a load/unload position between an entryinduction station 121 and an exit induction station 123. In anotherexample, the system 100 can load raw food products into griddle modulesin a load position adjacent the entry induction station 121 and unloadcooked food products from griddle modules in an unload position adjacentthe exit induction station 123 (e.g., between the exit induction station123 and the load position). However, the system 100 can include anyother number of griddle modules and any other number of inductionstations in any other suitable configuration. In yet another example,the system 100 can load and unload food products from griddle modules ina single position, such as from the entry induction station 121 (whichcan thus be physically coextensive with the exit induction station 123).

Furthermore, the system 100 can include a number of griddle modulesapproximately equivalent to a time required to fully heat (or cook) afood product to done divided by a target rate of done food productsoutput by the system 100. For example, for a hamburger patty of massnecessitating up to 50 seconds to cook to well-done and for a targetoutput rate of one cooked hamburger patty per ten-second interval, thesystem 100 can include five griddle modules and five induction stations,and the system 100 can implement a static intra-station period of twelveseconds, including ten seconds of active heating and two seconds toadvance the griddle modules to a next position per intra-station period.In this example, a sequence of five intra-station periods can thusdefine one cook cycle for one food product.

8. Base

As shown in FIGS. 1 and 4, the system 100 includes a base 130: includinga barrier; supporting a lower coil of an induction station on a firstside of the barrier; and supporting an upper coil of an inductionstation on a second side of the barrier opposite and aligned with thelower coil of the induction station for each induction station in theset of induction stations. Generally, the base 130 houses the lowercoils of the induction stations, houses related power controllers andelectronic oscillators (e.g., “generator boards”), houses components ofthe conveyor system, and supports the upper induction heads 126, asdescribed above.

In one implementation, the base 130 defines an enclosure with anaperture facing the upper induction heads 126, and the aperture isenclosed by a barrier, such as a borosilicate glass plate or a barrierof any other suitable material exhibiting low ferromagnetism and/or lowferrimagnetism. The base 130 can house the lower coils and the generatorboards inside the enclosure with the lower coils adjacent the barrierand configured to output alternating magnetic fields through the barrierto lower plates of adjacent griddle modules.

9. Conveyor System

As shown in FIG. 1, the conveyor system includes a hub that supportsupper and lower plates of griddle modules between the barrier and theupper induction heads of the induction stations. The conveyor systemalso includes a hub actuator 141 arranged within the base and configuredto sequentially index a griddle module from the entry induction stationto an intermediate induction station in Block S140 and from theintermediate induction station to the exit induction station in BlockS142. Generally, the base houses multiple lower coils and supportsmultiple upper induction heads, each including an upper coil, and theconveyor system positions griddle modules vertically between inductionstations and indexed griddle modules through the set of inductionstations as raw food products are sequentially loaded into the griddlemodules in the entry induction station, cooked throughout the set ofinduction stations, and then removed at the exit induction station, suchas for assembly with other ingredients into a hamburger.

The hub actuator 141 is arranged within (or is coupled to) the base andsupports the hub 140 above the barrier. In one implementation in whichthe griddle modules and induction stations are patterned radially aboutthe axis of the hub 140, the hub actuator 141 includes an electric motor(e.g., servo motor, stepper motor) and a gearbox, wherein an outputshaft of the gearbox is keyed and extends through a bore proximal thecenter of the barrier of the base to engage and support the hub 140above. In this implementation, the conveyor system can include a thrustbearing that vertically supports the hub 140 over the barrier, and theconveyor system can also include a seal—arranged about the thrustbearing—that resists ingress of debris (e.g., water, fat, grease) pastthe barrier and into the base. In this implementation, the system 100can include a position sensor that outputs a signal corresponding to theangular position of the motor, of the gearbox, of the output shaft, ofthe hub 140, or of a griddle module, and the system 100 can implementclosed-loop feedback techniques to position griddle modules in alignmentwith the induction stations based on outputs of the position sensor. Forexample, the conveyor system can include an optical encoder wheelcoupled to a keyed shaft and an optical encoder reader adjacent thewheel. The conveyor system can additionally or alternatively include anoptical sensor, limit switches, and/or other sensors arranged in a baseand/or on an upper induction head and outputting signals correspondingto the angular position of the hub 140; and the system 100 can controlthe hub actuator 141 to reposition the hub 140 during operation of thesystem 100 accordingly.

Alternatively, the conveyor system can include gearbox including aGeneva mechanism. In this implementation, the indexing wheel of theGeneva mechanism can be coupled to the hub 140, and the conveyor systemcan run the hub actuator 141 at a substantially constant speedintermittently rotating the indexing wheel through a sequence of indexpositions corresponding to the induction stations. In thisimplementation, the system 100 can set a speed of the hub actuator 141based on a target intra-station period and an effective gear reductionof the Geneva mechanism, and the conveyor system can implement closedloop controls to maintain the output speed of the hub actuator 141accordingly.

In Blocks S130 and S132, the system 100 can also deactivate (e.g., cutpower to) the upper and lower coils of the induction stations prior toadvancing the hub 140—and therefore the griddle modules—to a nextangular position in Blocks S140 and S142 in order to prevent the uppercoil of a induction module from inductively coupling to the lower coilof the induction module, which may damage a generator board connected tothe induction module, as described above.

In one configuration, the hub 140 supports both the upper and lowerplates of each griddle module in a radial pattern, and the hub actuator141 rotates the hub 140 to advance griddle modules—cantilevered off ofthe hub 140—along an arcuate path through each induction stationarranged in a circular pattern about the base, as shown in FIG. 2. Inone implementation, the system 100 includes multiple (e.g., five)induction stations arranged in a radial pattern about a center axis ofthe base; the hub 140 is arranged over an axial center of the barrierand supports upper and lower plates of multiple (e.g., five) griddlemodules in a corresponding radial pattern; and the hub actuator 141rotates the hub 140 through a sequence of angular positions radiallyoffset by 72° to sequentially index the griddle modules through theinduction stations. In this configuration, the hub 140 can includemultiple (e.g., five) vertical posts, each engaging an upper platereceptacle 113 of one griddle module such that each upper platereceptacle 113 can slide linearly (e.g., vertically) along itscorresponding post 143, as described above. For example, the system 100can raise an upper induction head at the entry induction station to liftan upper plate of a griddle module positioned in the entry inductionstation, and the upper plate receptacle 113 can slide along itscorresponding post 143 in the hub 140 to follow the upper inductionhead; the system 100 can then lower the upper induction head to releasethe upper plate toward its lower plate once a new food product has beendispensed onto the lower plate and before (or as) the upper and lowercoils of the entry induction station are activated to heat the upper andlower plates, respectively. Upon the conclusion of each intra-stationperiod, the hub actuator 141 rotates the hub 140 forward, therebyadvancing each griddle module into a subsequent induction station. Whena griddle module enters the exit induction station and a heating periodat the exit induction station is completed (e.g., over a portion of theintra-station period), the system 100 elevates the upper induction headof the exit induction station, which draws the upper plate receptacle113 up its post 143 on the hub 140 to reveal a cooked food product, andthe system 100 triggers the retrieval system to collect the food productfrom the griddle module.

Alternatively, the system 100 can include multiple induction stationsarranged in a linear array. In this configuration, the hub 140 cansupport the upper and lower plates of the griddle modules in a similarlinear array, and the hub actuator 141 can linearly advance the griddlemodules along the linear array of induction stations. For example, thesystem 100 can include: a linear array of five induction stations,including an entry induction station, three intermediate inductionstations 122, and an exit induction station arranged in a line; ten (ormore) griddle modules; a hub including a continuous linear conveyorconfigured to advance a griddle module from the entry induction stationto the exit induction station and to return the griddle module to theentry induction station when driven in a single direction by the hubactuator 141.

However, the system 100 can include any other number of inductionstations and griddle modules arranged in any other pattern, array orconfiguration, and the conveyor system can transition griddle modulesthrough each induction station throughout operation.

11. Insertion System

As shown in FIGS. 6 and 7, one variation of the system 100 includes aninsertion system 150 configured to place a food product onto the lowerplate of a griddle module positioned in the entry induction station.Generally, the insertion system 150 functions to dispense a food productinto a griddle module in the entry induction station in preparation toheat or cook the food product.

In one implementation, the system 100 interfaces with a patty grindingsystem that grinds chunks of meat, meters discrete masses or volumes ofground meat, and presses meat patties; and the insertion system 150includes a platen, a pusher, and an actuator that retracts the pusherand the platen into the grinding system to collect a patty, advances theplaten into a dispense position between the upper and lower plates of agriddle module in the entry induction station, and then advances thepusher—relative to the platen—to propel the patty off of the platen andonto the lower plate of the griddle module. However, the insertionsystem 150 can be of any other format and can function in any other wayto transfer a food product into a griddle module in the entry inductionstation in Block S112. In another implementation, the insertion system150 includes a cup, a piston running within the cup, a boom supportingthe cup on one end, and an actuator system. In this implementation, theactuator system positions the cup inside the grinder system, the grindersystem loads a food product (e.g., ground meat) into the cup, and theactuator system then advances the cup outside of the grinder system andinto the griddle module in the entry induction station, inverts the cup,and drives the piston forward to push the food product out of the cupand onto the lower plate of the griddle module before resetting thepiston and cup and returning the cup to the grinder system.

12. Retrieval System

As shown in FIG. 2, the retrieval system 150 includes a paddle 161 and aretrieval actuator 162 that selectively advances the paddle 161 across alower plate of a griddle module in the exit induction station toretrieve a patty from the lower plate. Generally, the retrieval system150 includes an arm, a paddle 161, and a retrieval actuator 162 thatcooperate to collect a heated or cooked food product from a griddlemodule in the exit induction station.

In one implementation, the retrieval actuator 162 includes an arm, apaddle 161 cantilevered from the distal end of the arm and droopingslightly downward (e.g., at an angle of 2° from the top surface of thelower plate of an adjacent griddle module) in an initial position, and aretrieval actuator 162 configured to position the arm between a collectposition within the exit induction station and a nearby dispenseposition. In this implementation, to remove a patty from a griddlemodule at the exit induction station in Block S162, the system 100triggers an exit elevation actuator 127 to raise the upper inductionhead of the exit induction module, which catches the skid 116 extendingfrom the upper plate receptacle 113 of the adjacent griddle module andseparates the upper plate from its corresponding lower plate. The system100 then triggers the retrieval actuator 162 to swing or extend the armtoward the exit induction station. As the paddle 161 approaches thegriddle module, retrieval actuator 162 drives the leading edge of thepaddle 161 downward and into contact with the top surface of the lowerplate, thereby deflecting the tip of the paddle 161 upward. Theretrieval actuator 162 then drives the paddle 161 toward a backstop onor adjacent the lower plate (as described below), which constrains thefood product as the paddle 161 is inserted between the patty and thelower plate. For example, the paddle 161 can define a tip initiallydeclined downward at a first angle below horizontal, and the retrievalactuator 162 can drive the tip of the paddle 161 downward against thetop surface of the lower plate in the exit induction station until thetip of the paddle 161 is declined downward at a second angle less thanthe first angle below horizontal, thereby compressing the tip of thepaddle 161 against the top of the lower plate to enable the tip of thepaddle 161 to scrape the food product from the lower plate substantiallywithout piercing the food product as the retrieval actuator 162 pivotsor extends the paddle 161 laterally (e.g., horizontally) to collect thefirst food product from the lower plate onto the paddle 161 in BlockS162. The retrieval actuator 162 then raises the arm—which raises thepaddle 161 and the food product off of the lower plate—and advances thepaddle 161 into the dispense position over an adjacent conveyorsupporting a box, a plate, or a bun, etc. below. In this implementation,the retrieval system 150 also includes a ledge 163 arranged over theconveyor, and the retrieval actuator 162 sweeps the paddle 161 past theledge 163, which constrains the food product as the retrieval actuator162 draws the paddle 161 past the ledge 163, thereby displacing the foodproduct from the paddle 161 and onto a hamburger bun (or into a box,onto a plate, onto a salad, etc.) supported on the conveyor below.

In the foregoing implementation, the ledge 163 can also include anintegrated scraper, squeegee, or other like structure configured to wipeor scrape waste—such as grease or loose particles from the foodproduct—from the paddle 161 as the retrieval actuator 162 draws thepaddle 161 past the ledge 163. For example, the retrieval actuator 162can pivot the paddle 161 in a first direction—from the ledge 163 towardthe exit induction station—with the tip of the paddle 161 leading tocollect a food product from a griddle module in the exit inductionstation, and the retrieval actuator 162 can then pivot the paddle 161 inan opposite direction—back toward the ledge 163—with the tip of thepaddle 161 trailing to draw the paddle 161 past the ledge 163 andintegrated scraper, thereby driving the food product and food wastecollected on the paddle 161 off of the paddle 161 and toward theconveyor below. Furthermore, in this implementation, the ledge 163 caninclude two opposing scrapers, squeegees, or other like structures, andthe retrieval actuator 162 can draw the paddle 161 through a voidbetween the opposing structures to clean food waste from both sides ofthe paddle 161. However, the ledge 163 can include any other one or morefeatures configured to dispel food waste from the paddle 161, and theretrieval actuator 162 can manipulate the paddle 161 in any other wayand between any other positions to collect a food product from the exitinduction station and to dispense the food product onto a hamburger bun,box, or plate, etc.

As described above, a griddle module can also include a backstopconfigured to prevent a food product arranged on the lower plate fromfalling off the lower plate and onto the base, such as when theretrieval system 150 retrieves a heated or cooked food product from thelower plate in the exit induction station. For example, for theretrieval system 150 that extends a paddle 161 longitudinally toward thehub to collect a food product from griddle modules in the exit inductionstation, a lower plate (and the upper plate) in a griddle module caninclude a backstop extending vertically from its cook surface along asection of the perimeter of the lower plate facing the hub andconfigured to function as a backstop to prevent a food product fromshifting toward the hub and off the lower plate when the retrievalsystem 150 is actuated to collect the food product in Block S162.Similarly, for the retrieval system 150 that extends a paddle 161laterally across a lower plate to collect a food product from the lowerplate, the lower plate (and the corresponding upper plate) can include abackstop extending vertically from its cook surface along one side ofthe perimeter of the lower plate opposite the approach direction of theretrieval system 150 to prevent a food product from shifting away fromthe tip of the paddle 161 as the paddle 161 is driven between the foodproduct and lower plate in Block S162. Alternatively, the hub caninclude a backstop extending toward the perimeter of the lower platebetween the upper and lower plates of the griddle module and can befixed in position relative to the griddle module. Yet alternatively, thesystem 100 can include static backstops fixedly (e.g., intransiently)supported by the base adjacent each induction station. However, thesystem 100 can include one or more backstops of any other form andmounted to any other one or more elements within the system 100.

13. Waste Management

As shown in FIG. 5, one variation of the system 100 includes a wastemanagement system 170 that collects debris (e.g., water, fat, grease)released by food products heated or cooked in the system 100 duringoperation.

In one implementation in which the base defines a circular or polygonalcross-section and supports induction stations in a radial array, thewaste management system 170 includes: a trough arranged about aperimeter of base and defining a valley below the barrier. In thisimplementation, the waste management system 170 can also include a wiper142 mounted to the hub (or to a lower plate or lower plate receptacleinstalled on the hub), extending across a surface of the barrier, andconfigured to drive food waste deposited onto the barrier toward thetrough during rotation of the hub. In particular, the wiper 142 canscrape debris from the surface of the barrier and drive this debris intothe trough as the hub rotates. For example, the wiper 142 can include asilicon wiper blade defining a curvilinear profile extending fromproximal the center of the hub, past the end of the barrier, and intothe trough. In this example, the wiper 142 can also define a curvilinearprofile spiraling outward from the center of the hub opposite thedirection of rotation of the hub in order to drive waste collecting onthe barrier outwardly toward the trough. As the hub actuator rotates thehub, the wiper 142 can thus wipe fats, water, and other waste collectingon the barrier toward the trough, such as to maintain a relatively cleanbarrier, to manage waste, and/or to maintain substantially consistentinductive coupling between lower coils and adjacent lower plates byremoving waste that may otherwise absorb the magnetic fields' output bythe lower coils.

In this implementation, the trough can extend along an edge of thebarrier and can define a drain, and the waste management system 170 canalso include: a collection canister 173; a conduit 172 extending from abase of the trough to the collection canister 173; and a heating element171 arranged on the conduit 172, as shown in FIG. 5. The collectioncanister 173 can be arranged in the base below the trough, and theheating element 171 can maintain the temperature of the conduit 172(and/or the trough and/or the collection canister 173) above a commonflow temperature of waste released from food products loaded into thesystem 100 (e.g., above 160° F., a common flow temperature of meat fat)in order to prevent obstruction of the conduit 172 by cooled andhardened waste. The waste management system 170 can additionally oralternatively include a discrete heating element thermally coupled tothe trough and configured to maintain the trough above such a thresholdtemperature, or the trough can be thermally coupled to the barrier,which can maintain the temperature of the trough above the thresholdtemperature during operation; the waste management system 170 cansimilarly include a discrete heating element thermally coupled to thecollection canister 173 and configured to maintain the collectioncanister 173 above such a threshold temperature. However, the wastemanagement system 170 can maintain the trough, the drainage line, and/orthe collection canister 173 at an elevated temperature in any other wayin order to limit coagulation and collection of fats and other debris inthe trough, in the drainage line, and along walls of the collectioncanister 173.

In this implementation, the waste management system 170 can includeadditional wipers extending across the barrier—such as arranged in aradial pattern about the hub—and configured to drive debris from thesurface of the barrier into the trough. Each wiper 142 can also extendfrom the surface of the barrier into the trough and can thus drive wastein the trough forward and toward the drain as the hub is rotated,thereby limiting collection of debris in the trough.

14. Plate Scraper

One variation of the system 100 further includes a plate scraperconfigured to scrape debris from the upper plate and/or the lower plateof a griddle module as the system 100 advances the griddle module fromthe exit induction station back to the entry induction station inpreparation to receive a next food product. Generally, the plate scraperfunctions to scrape grease, water, grizzle, meat particles, etc. fromthe upper plate and/or the lower plate in a griddle module as theconveyor system advances the griddle module from the exit inductionstation back to the entry induction station and in preparation toreceive a new food product in Block S112.

In one implementation, the plate scraper is fixedly mounted to the basebetween the exit induction station and the entry induction station andincludes an upper silicon wiper blade (e.g., like the wiper describedabove) and a lower silicon wiper blade sprung outwardly and configuredto scrape the lower surface of the upper plate and the upper surface ofthe lower plate, respectively, of a griddle module as the hub advancesthe griddle module from the exit induction station to the entryinduction station. Alternatively, the plate scraper can include a staticstainless steel bristle brush or an active (e.g., oscillating, rotating)stainless steel bristle brush that scrapes debris from the upper andlower plates as the griddle module is advanced past the plate scraper.The plate scraper can thus passively or actively abrade the cookingsurfaces of the upper and lower plates of a griddle module as thegriddle module transitions from the exit induction station to the entryinduction station, thereby removing waste and reducing a surface contactarea of the cooking surfaces to reduce opportunity for a new foodproduct dispensed into the griddle module in Block S112 from sticking tothe upper and lower plates of the griddle module.

The system 100 can also include a grease module arranged between theexit and entry induction stations, such as interposed between the platescraper and the entry induction station. For example, the grease modulecan include one or more nozzles—arranged between the exit and entryinduction stations—that spray water, butter, and/or cooking oil, etc.onto the opposing cooking surfaces of the upper and lower plates of agriddle module as the conveyor system advances the griddle module fromthe exit induction station to the entry induction stations, such asimmediately after the upper and lower plates are scraped by the platescraper.

15. Temperature Sensing

As shown in FIGS. 3, 4, 6 and 8, one variation of the griddle moduleincludes a temperature sensor 114 that outputs a signal corresponding tothe temperature of an upper and/or lower plate in the griddle module,and the system 100 samples the temperature sensor 114 during operationto track the temperature of the upper and/or lower plates and adjustspower outputs of the upper and lower coils of the induction stationsaccordingly. For example, the system 100 (e.g., the controller 180) canimplement closed-loop feedback techniques to modulate the power outputsof the upper and lower coils of the induction stations to achieve asingle target temperature of the upper and lower plates of a griddlemodule, to achieve a sequence of target temperatures in the upper andlower plates of the griddle module, to achieve a target heat flux into afood product arranged in the griddle module, etc. during a cook cyclebased on outputs of the temperature sensor(s) 114 and a doneness valuespecified for the food product. (Alternatively, the system 100 canadjust an intra-station period at an induction station based on outputsof the temperature sensors 114 in order to achieve a doneness valuespecified for a corresponding food product.)

In one implementation, a griddle module includes a contact-basedtemperature sensor 114, such as a thermocouple, thermistor, resistancetemperature detectors (RTDs), or silicon bandgap temperature sensor incontact with an upper plate in the griddle module. In one exampleimplementation, the upper plate of the griddle module includes: achannel on the back side of the upper plate—opposite a cookingsurface—and running from the tongue of the plate, along the back side ofthe upper plate, to the axial center of the upper plate; a temperaturesensor 114 arranged in the channel proximal the axial center of theplate; a sensor plug 119 (or sensor receptacle) arranged on the tongue;electrical leads arranged within the channel and electrically coupled tothe temperature sensor 114 and to the sensor plug (or sensorreceptacle); potting material arranged over the temperature sensor 114and the electrical leads within the channel; and a closing insertarranged within the channel and enclosing the temperature sensor 114,electrical leads, and potting material within the channel, as shown inFIG. 3. In this example implementation, the closing insert can be:dovetailed and press-fit into the channel that is similarly dovetailed;welded or brazed into the channel; mechanically fastened in the channel;or constrained within the channel in any other suitable way.

In the foregoing example, the hub can include an upper sensor leadreceptacle 149, such as integrated into the upper plate receptacle(shown in FIG. 3) or physically distinct from the upper plate receptacle113, and the sensor plug extending from the temperature sensor 114 inthe upper plate can mate with the upper sensor lead receptacle in theupper plate receptacle of the hub when the upper plate is installed inthe upper plate receptacle or when the upper plate and upper platereceptacle assembly are installed on the hub, as shown in FIG. 3.Therefore, the upper plate can include an integrated temperature sensor114 proximal an axial center of the upper plate and a sensor leadextending laterally from the temperature sensor 114, and the sensor leadcan transiently couple to the upper sensor lead receptacle in the hubduring operation of the system 100 and can be removed from the sensorlead receptacle with the upper plate, such as for cleaning. The lowerplate of the griddle module can similarly include an integratedtemperature sensor 114 proximal an axial center of the lower plate and asensor lead extending laterally from the temperature sensor 114, andthis sensor lead can similarly couple to and decouple from a lowersensor lead receptacle in the hub.

In another example, an upper plate in a griddle module defines a blindbore extending laterally from an edge of the plate (e.g., from thetongue) toward the axial center of the upper plate. In this example, thegriddle module includes a beam extending from the upper plate receptacle113 (or from the hub) and terminating in a temperature sensor 114. Inthis example, the beam can be inserted into the blind bore and cansupport the temperature sensor 114 inside of and proximal the axialcenter of the upper plate when the upper plate is installed in its upperplate receptacle 113.

In a similar example, the upper plate defines an open channel across itsback side opposite its cooking surface, wherein the open channel (suchas defining a dovetail cross-section) extends laterally from an edge ofthe plate to its axial center; and the griddle module includes a beam(e.g., of a dovetail cross-section) exceeding from the upper platereceptacle 113 (or from the hub) and terminating in a temperature sensor114. In this example, the beam can be inserted into the dovetail slot inthe upper plate as the upper plate is installed in its correspondingupper plate receptacle 113. In this and the foregoing examples, the beamcan include a conductive spring tip extending from the temperaturesensor 114, and the conductive spring tip can absorb variations inlocation of the plate relative to the beam over time to maintainsufficient thermal contact between a surface of the upper plate and thetemperature sensor 114 during operation.

In yet another example, an upper plate receptacle (or the hub) includesan external beam cantilevered over and sprung downward toward the backside of an upper plate when the upper plate is installed on the hub, asshown in FIG. 4. In this example, the system 100 can include atemperature sensor 114 supported on a distal end of the beam andconfigured to contact the back surface of the upper plate when the upperplate is installed in its correspond upper plate receptacle. Forexample, the beam can be of aluminum, of a polymer, or of any othermaterial exhibiting relatively low ferromagnetism and relatively lowferrimagnetism such that the beam—cantilevered between the upper plateand an adjacent coil—is not substantially heated by an oscillatingmagnetic field output by the adjacent coil, such as by Joule heating.The beam can also be of a substantially minimal cross-section to reduceabsorption of the magnetic field output by the adjacent coil, and thebeam can include a thermal break (e.g., a polymer insert) arrangedbetween a structural component of the beam and the temperature sensor114 to thermally isolate the temperature sensor 114 from the structuralcomponent of the beam. In this example, the temperature sensors 114 canbe similarly cantilevered off the upper induction heads or supporteddirectly by the base. However, the system 100 can include a temperaturesensor 114 supported over the back surface of an upper plate andconfigured to output a signal corresponding to the temperature of theback surface of the upper plate, and the temperature sensor 114 can befixed relative to the upper plate (e.g., coupled to the hub) and canmove with the upper plate as the hub rotates, or the temperature sensor114 can be fixed relative to the base and can output signalscorresponding to temperatures of adjacent upper plates as the hubrotates during operation.

In another implementation, induction stations in the system 100 includecontactless temperature sensor 114 that remotely detects the temperatureof an upper plate in the griddle module and outputs a signalaccordingly. In one example implementation, each griddle module includesa laser or infrared contactless temperature sensor 114, and each coil ineach induction station defines a window through its approximate center.In this example implementation, a contactless temperature sensor 114 canbe directed through a window in an upper coil of the induction stationand can output a signal corresponding to the temperature of the backsurface of the upper plate of a griddle module currently in theinduction station. Similarly, a contactless temperature sensor 114 cansense the temperature of an adjacent lower plate through the barrier viaa window through the center of the lower coil. In this exampleimplementation, the material of the non-magnetic window of the upperinduction head and the material of the barrier of the base can besubstantially transparent to electromagnetic radiation within arelatively narrow wavelength band, and the temperature sensors 114 caninclude laser or infrared contactless temperature sensors configured tooperate within this same wavelength band.

In this variation, the system 100 can include one contact-based orcontactless temperature sensor for each upper plate and lower plate ineach griddle module. For example, for a system with five inductionstations and five griddle modules, the system 100 can include tentemperature sensors 114, such as one temperature sensor 114 integratedinto each of the five upper plates and lower plates and electricallycoupled to sensor lead receptacles in the hub. In this example, all tentemperature sensors 114 can be substantially identical and arrangedwithin the system 100 in substantially the same way (e.g., integratedinto or separate from and cantilevered toward a corresponding plate).Alternatively, the system 100 can include different types of temperaturesensors, such as five contactless (e.g., infrared) lower temperaturesensors 114 arranged within the base and configured to output signalscorresponding to the temperatures of adjacent lower plates and fivecontact-based upper temperature sensors 114 cantilevered off of the hub,contacting the back surfaces of the upper plate receptacles, andconfigured to output signals corresponding to temperatures of upperplates.

In the foregoing variations in which the system 100 includes temperaturesensors 114 integrated into plates or supported off of the hub or platereceptacles, the system 100 can further include a slip ring assembly144—as shown in FIGS. 4 and 6—arranged between the hub and the base andconfigured to communicate signals from the temperature sensors 114 intothe base, such as to the controller 180 arranged within the base. Forexample, for the system 100 that includes five griddle modules, fiveinduction stations, five upper plates, five lower plates, and tentemperature sensors 114, the hub can include a slip ring assemblyincluding one ground ring and ten sense rings, including one sensingring per temperature sensor 114 configured to communicate an analogtemperature signal from a temperature sensor 114 to the controller 180in the base. Alternatively, the system 100 can include a signalprocessing unit (SPU) arranged within the hub, and the SPU can sampleeach of these temperature sensors 114, transform analog temperaturesignals into digital temperature values, and then transmit these digitaltemperature values via a limited number of channels (e.g., low-currentdata lines) in the slip ring assembly to the controller 180. Forexample, in this implementation, the slip ring assembly can include oneground ring, one power ring to supply power to the SPU, and one or moredata rings over which the SPU transmits digital temperature values forall temperature sensors 114 into the base (e.g., over I2C communicationprotocol).

In a similar implementation, the system 100 includes a wirelesstransmitter arranged within the hub, coupled to the SPU, and configuredto wirelessly broadcast digital temperature values from the SPU to aremote wireless receiver, such as within the base and electricallycoupled to the controller 180. In this implementation, the SPU and thewireless transmitter can be powered by a rechargeable batterytransiently installed within the hub. Alternatively, the wirelesstransmitter and the SPU can be powered by an inductive energy harvesterarranged within or coupled to the hub, configured to harvest energy froma magnetic field output by dedicated inductive coil in the base or in anupper induction head or to siphon energy from magnetic fields output bycoils in the induction stations, and to condition (e.g., rectify) thisenergy to power the wireless transmitter and/or to charge a battery inthe hub while the system 100 is in operation.

16. Controller and Temperature Control

As shown in FIG. 5, one variation of the system 100 includes acontroller 180 configured to control the positions of a griddle modulein the induction stations via the hub actuator and to control the poweroutput of coils in the induction stations during a cook cycle. Forexample, the controller 180 can modulate power outputs of upper andlower coils in the induction stations based on a position of the griddlemodule and a temperature value received from the temperature sensors inorder to achieve a target heat flux into a food product, to achieve atarget temperature of the food product, and/or to achieve a targettemperature or temperature profile of the upper and lower plates of thegriddle module containing the food product corresponding to a donenessvalue selected for the food product.

In this variation, the system 100 can be configured to cook a foodproduct to a single doneness value (e.g., “medium” or “medium-well”)corresponding to a total target heat flux through the upper and lowerplates in a griddle module, calculated as the sum of the integral oftemperatures of the upper plate of the griddle module and the integralof temperatures of the corresponding lower plate during a cook cycle.The controller 180 can also calculate or implement a total targetintra-station heat flux, such as calculated by multiplying the totaltarget heat flux by the intra-station period and dividing this productby the total time of a cook cycle. Thus, during a cook cycle, thecontroller 180 can sample temperature sensors coupled to or integratedinto the upper and lower plates of a griddle module containing a foodproduct, such as at a rate of 1 Hz; during each intra-station period inwhich the griddle module is positioned within an induction station, thecontroller 180 can implement closed-loop feedback controls to modulatethe power outputs of coils in the induction station to achieve the totaltarget intra-station heat flux upon expiration of the intra-stationperiod and before shifting the griddle module forward to a nextinduction station. The controller 180 can thus independently controlpower outputs of each coil in each induction station to achieve a totaltarget heat flux through the upper and lower plates of a griddle moduleduring a cook cycle to achieve a single doneness value of a foodproduct.

The controller 180 can also store multiple discrete doneness values forfood products. For example, the controller 180 can store discrete presettotal target heat flux values (and/or preset target intra-station heatflux values) for each of “rare,” “medium-rare,” “medium,” “medium-well,”and “well-done” doneness values. In one example in which the system 100is integrated into an automated foodstuff assembly apparatus, theautomated foodstuff assembly apparatus 200 can receive a hamburger orderfrom a patron, wherein the hamburger order specifies a doneness—selectedfrom the foregoing set of five available doneness values—for a hamburgerpatty. In this example, the controller 180 receives a request to preparea hamburger patty of this doneness value from the automated foodstuffassembly apparatus 200 and then selects a total target heat flux value(and/or target intra-station heat flux value) corresponding to thisspecified doneness for the hamburger patty. Once an adjacent grindersystem grinds, presses, and dispenses a new hamburger patty onto thelower plate of a griddle module in the entry induction station, thecontroller 180 modulates the outputs of the upper and lower coils of theentry induction station to achieve the target intra-station heat fluxvalue at the induction station during a first intra-station period; thecontroller 180 then repeats this process for each intermediate inductionstation and for the exit induction station to produce a hamburger pattyat the specified doneness upon conclusion of the cook cycle; the system100 then releases the cooked hamburger patty to a hamburger bun, box,plate, or other container in Block S162.

Alternatively, the controller 180 can implement a parametric model tocalculate total target heat flux values (and/or target intra-stationheat flux values) for quantitative (e.g., rather than qualitative)doneness values selected from a continuum of quantitative donenessvalues. In one example shown in FIG. 8, a patron can generate ahamburger order within an ordering interface executing on a mobilecomputing device (e.g., a smartphone) or at a local kiosk connected tothe automated foodstuff assembly apparatus; within the orderinginterface, the patron can manipulate a slider along a slider bar toselect a doneness value for a hamburger patty in the patron's hamburgerorder, such as quantitative doneness value between 1 and 100 along a100-increment slider bar. Upon receipt of this hamburger order, theautomated foodstuff assembly apparatus 200 can distribute a request fora new hamburger patty—cooked to the selected doneness value—to thecontroller 180, and the controller 180 can calculate the total targetheat flux value and/or target intra-station heat flux value for thehamburger patty by passing the selected quantitative doneness value intoa parametric model. The controller 180 can then modulate the poweroutputs of coils in the induction stations throughout a cook cycle toachieve the total target heat flux value and/or target intra-stationheat flux value for the hamburger patty before releasing the cookedhamburger patty in Block S162 for assembly with other ingredientsspecified in the patron's hamburger order.

The system 100 can also be configured to receive food products ofdifferent sizes in Block S112, and the controller 180 can select andimplement a total target heat flux value and/or a preset targetintra-station heat flux value for a food product based on its size. Forexample, the system 100 can receive hamburger patties from a grindersystem in Block S112, wherein the grinder system is configured to grindand press patties of two different sizes, such as one-quarter-pound andone-half-pound hamburger patties; and the controller 180 can select apreset total target heat flux value and/or a preset target intra-stationheat flux value for a hamburger patty based on a size of the hamburgerpatty such as either a first heat flux for one-quarter-pound hamburgerpatties or a second heat flux less than the first heat flux forone-half-pound hamburger patties.

Similarly, the system 100 can also be configured to receive foodproducts of different types in Block S112, and the controller 180 canselect and implement a preset total target heat flux value and/or apreset target intra-station heat flux value for a food product based onits types. For example, a grinder system can be configured to grind 100%beef hamburger patties, 100% turkey hamburger patties, and 50% beef/50%turkey hamburger patties; and the controller 180 can select a presettotal target heat flux value and/or a preset target intra-station heatflux value for a hamburger patty based on its composition, such asincluding a first heat flux for 100% beef hamburger patties, a secondheat flux less than the first heat flux for 50% beef/50% turkeyhamburger patties, and a third heat flux less than the second heat fluxfor 100% turkey hamburger patties.

The controller 180 can additionally or alternatively select a presettotal target heat flux value and/or a preset target intra-station heatflux value for a food product based on the fat content (or proteincontent, etc.) of the food product. For example, the controller 180 canaccess nutritional data entered from a container of meat loaded into theadjacent grinder system for an average or actual fat content of thisvolume of meat and then select a preset total target heat flux valueand/or a preset target intra-station heat flux value for hamburgerpatties formed from this volume of meat. In this example, the automatedfoodstuff assembly apparatus 200 can include a scanner (e.g., a barcodescanner, an RFID scanner) configured to retrieve data from a containerof meat loaded into the grinder system, can interface with an external(e.g., a handheld) scanner to access such data scanned from thecontainer, can receive a meat type and/or meat data (e.g., fat content,protein content) entered manually by an operator through an integratedor connected user interface, or access these data in any other way, andthe controller 180 can then implement a first heat flux for hamburgerpatties with 10% fat content and can implement a second heat fluxgreater than the first heat flux for hamburger patties with 20% fatcontent.

Similarly, the controller 180 can select a preset total target heat fluxvalue and/or a preset target intra-station heat flux value for a foodproduct based on a level of compaction or density of the food product.For example, the grinder can be configured to compact ground meat to oneof two compaction levels to form a hamburger patty, such as a loosecompaction for rare hamburger patties and a tight compaction forwell-done hamburger patties. In this example, the controller 180 can:select a first intra-station heat flux value for a loose compactionpatty assigned a rare doneness value; select a second intra-station heatflux value greater than the first intra-station heat flux value for aloose compaction patty assigned a medium-rare doneness value; select athird intra-station heat flux value for a tight compaction pattyassigned a medium doneness value; and select a fourth intra-station heatflux value greater than the third intra-station heat flux value for atight compaction patty assigned a well-done doneness value.

The controller 180 can also select a preset total target heat flux valueand/or a preset target intra-station heat flux value for a food productbased on the initial temperature of the food product. For example, thecontroller 180 can sample outputs of a temperature sensor installedwithin the grinder system to determine the initial temperature of ahamburger patty and then implement a first heat flux for hamburgerpatties within a first initial temperature range and can implement asecond heat flux greater than the first heat flux for hamburger pattieswithin a second initial temperature range less than the first initialtemperature range. The controller 180 can implement similar methods andtechniques to select a preset total target heat flux value and/or apreset target intra-station heat flux value for a food product based onthe initial temperatures of the upper and lower plates in a griddlemodule when loaded with a new food product in Block S112.

In the foregoing implementations, the controller 180 can access andimplement one or more lookup tables containing preset total target heatflux values and/or preset target intra-station heat flux values forvarious combinations of food product sizes, selected doneness values,food product compaction level or density, food product compositions,initial food product temperatures, initial upper and lower platetemperatures, etc., as shown in FIG. 8. Alternatively, the system 100can implement one or more parametric models to determine anintra-station target heat flux for a food product. For example, thecontroller 180 can pass a hamburger patty size, a selected donenessvalue, an intra-grinder compaction value, a hamburger patty composition(e.g., meat type, fat content, protein content), a hamburger pattycompaction level or density, an initial hamburger patty temperature,and/or initial upper and lower plate temperatures, etc. directly into aparametric module to calculate an intra-station target heat flux for anew hamburger patty before or as the hamburger patty is loaded into agriddle module in the entry induction station in Block S112. Thus, inthis example, the system 100 can implement a parametric model tocalculate target temperatures of the first lower plate and the firstupper plate at each of the entry induction station, the intermediateinduction station, and the exit induction station based on a fat andprotein composition of the first food product including a ground meatpatty, a compaction value of the first food product, an initialtemperature of the first food product, and a duration of the cook cycleor intra-station period. Alternatively, the controller 180 can pass oneor more of the foregoing parameters into one or more lookup tables toretrieve corresponding coefficients and then pass these coefficientsinto a parametric model to calculate an intra-station target heat fluxfor a food product.

In the foregoing implementations, the controller 180 can also select orcalculate induction station-specific intra-station target heat fluxvalues for a food product. For example, the controller 180 can selectand implement a high heat flux value for the entry induction station tosear the top and bottom of a hamburger patty during the firstintra-station period of a cook cycle and then select and implement lowerheat flux values for the intermediate and exit induction stations tocook the hamburger patty through its thickness before releasing thehamburger patty in Block S162, as shown in FIG. 8. The controller 180can thus select or calculate a target heat flux over a staticintra-station period at each induction station to heat or cook a foodproduct to a selected doneness for the food product over the course of acook cycle.

Furthermore, the controller 180 can translate an intra-station targetheat flux into a single target temperature or a sequence of targettemperatures for the upper and lower plates of a griddle modulethroughout a cook cycle, as shown in FIG. 8, and the controller 180 canimplement closed-loop feedback techniques to modulate the power outputsof the upper and lower coils of the induction stations in order toachieve these target temperatures in the upper and lower plates of thegriddle module. In this variation, the method 100 can include:calculating target temperatures of the first lower plate and the firstupper plate at each of the entry induction station, the intermediateinduction station, and the exit induction station based on a donenessvalue assigned to the first food product in Block S110; tracking actualtemperatures of the first lower plate and the first upper plate in thefirst griddle module between the first period of time and the sixthperiod of time in Block S172; and modulating power outputs of lowercoils and upper coils of the entry induction station, the intermediateinduction station, and the exit induction station based on differencesbetween the target temperatures and the actual temperatures of the firstlower plate and the first upper plate in Blocks S120, S122, and S124,etc., and the controller 180 can implement these Blocks of the method100 throughout a cook cycle.

The controller 180 can thus modulate the power outputs of the upper andlower coils of the induction station—thereby controlling a heat fluxfrom the upper and lower plates of a griddle module—during a cook cyclebased on outputs of a temperature sensor thermally coupled to the upperand lower plates, a doneness value specified for a food product, and/orvarious other measured or entered parameters throughout a cook cycle ofstatic duration, as shown in FIG. 8. The controller 180 can additionallyor alternatively vary the duration of a cook cycle or an intra-stationperiod to cook a food product to a specified doneness. For example, thecontroller 180 can immediately open a griddle module upon entry into theexit induction station in Block S160 and trigger the retrieval system toretrieve a food product contained therein in Block S162 if the foodproduct is assigned a rare doneness level; and the controller 180 cansupply power to the upper and lower coils of the exit induction stationfor a full intra-station duration before triggering the retrieval systemto retrieve a food product contained therein in Block S162 if the foodproduct is assigned a well-done doneness level.

For the system 100 that includes multiple griddle modules, thecontroller 180 can simultaneously and independently control the poweroutputs of each induction station module to achieve a target heat flux(or target plate temperatures) at each griddle module during eachintra-station period in order to cook each food product to a specifieddoneness level independent of other food products simultaneously inprocess in the system 100. For example, the controller 180 can implementmethods and techniques described above to simultaneously process a rarehamburger patty, a medium-rare hamburger patty, a medium hamburgerpatty, a medium-well hamburger patty, and a well-done hamburger patty.

For example, the controller 180 can execute the foregoing Blocks of themethod 100 for each griddle module and induction station in the system100 and can repeat this process as the hub conveyor moves griddlemodules through sequential induction stations in order to achieve atarget doneness for each hamburger patty exiting the system 100. In thisexample, the controller 180 can receive an order for a hamburger patty,including a doneness specification for the hamburger patty, and thecontroller 180 can select a temperature profile for the hamburger pattybased on the doneness specification. In this example, a temperatureprofile can be specific to a particular doneness specification and candefine a target temperature of the upper and lower plates at eachinduction station, such as based on the intra-station period and a knowntransition time between induction stations. In this example, atemperature profile can also define a peak target temperature for theupper and lower plates of a griddle module when the griddle module isarranged within the entry induction station, and the temperature profilecan define a minimum temperature of the upper and lower plates when thegriddle module is arranged in the exit induction station such that theupper and lower plates can be quickly and actively heated to a new peaktemperature specific to a temperature profile of a subsequent hamburgerpatty to be loaded into the griddle module once the griddle module isadvanced into the entry station, thereby reducing or eliminating a waittime for the upper and lower plates to cool to an entry targettemperature when the griddle module releases a well-done patty andprepares to receive a new patty with a ‘rare’ specification.

However, the controller 180 can implement any other controls ortechniques to control the power outputs of coils in the inductionstations.

17. Dynamic Plate Offset

In one variation shown in FIG. 7, the method 100 includes Block S180,which recites, calculating a compression distance for the first foodproduct based on the doneness value assigned to the first food product,and Block S182, which recites driving a compression actuator 128 coupledto the upper coil in the intermediate induction station to a targetposition corresponding to the compression distance in order to set amaximum compression of the first food product between the first lowerplate and the first upper plate in the intermediate induction station.Generally, in this variation, the controller 180 can calculate a targetcompression distance for a product based on a doneness value selectedfor or assigned to the food product and can drive an elevation actuator127 (or a compression actuator 128, as described below) to a targetvertical position corresponding to the target compression distance forthe food product in order to control a cook rate of the food product.

In this variation, a griddle module includes a compression actuator 128that functions to adjust an offset height between opposing cookingsurfaces of the upper and lower plates of a griddle module. Inparticular, by actively compressing the upper and lower plates of agriddle module, the system 100 can cook a food product at an increasedrate. Similarly, by lowering a stop between the upper and lower platesof the griddle module and permitting the upper plate to compress a foodproduct below, the system 100 can cook a food product at an increasedrate. The system 100 can therefore actively compress the upper plate ofa griddle module or control the position of a lower stop for the upperplate in the griddle module in order to control the cook rate of a foodproduct loaded into the griddle module.

In one implementation in which an upper plate receptacle includes a skid116 configured to couple to an adjacent upper induction head and inwhich the system 100 includes an elevation actuator 127 configured toset the vertical position of the upper induction head, the elevationactuator 127 can shift the vertical position of the upper induction headto a position corresponding to a minimum offset distance between theopposing cooking surfaces of the upper and lower plates of the adjacentgriddle module. For example, if the minimum offset distance between theopposing cooking surfaces of the upper and lower plates of the griddlemodule is less than the current thickness of the food product, theweight of the upper plate and upper plate receptacle can draw the upperplate downward to compress the food product onto the skid 116 bottom onthe upper induction head, thereby setting a maximum compression distancefor the food product. The elevation actuator 127 can thus function as acompression actuator 128.

In the foregoing implementation, a skid 116 extending from the upperplate receptacle of the griddle module can thus extend up to and over atop surface of the upper induction head and can draw the upper plateupward (i.e., away from the lower plate) as the elevation actuator 127raises the upper induction head. Similarly, when the elevation actuator127 drops the upper induction head, the skid 116 can lower with theupper induction head, thus lowering the upper plate back toward thelower plate. Furthermore, once the upper plate reaches and is supportedvertically by the food product below, the controller 180 can continue todrive the upper induction head downward to a position corresponding tothe target compression distance; the upper induction head can thuscontact the top surface of the upper plate and force the upper platedownward, thereby compressing the food product, as shown in FIG. 7. Forexample, the upper induction head can be supported by a parallelfour-bar linkage and counterweighted (e.g., with a gas strut), and theelevation actuator 127 can be coupled to the parallel four-bar linkageto actively raise and lower the upper induction head such that the upperinduction head remains substantially parallel to the barrier throughoutits travel range. In another example, the upper induction head ismounted directly to a linear actuator configured to raise and lower theupper induction head along a vertical linear trajectory.

The system 100 can thus receive a food product, such as in the form of athick hamburger patty, at a griddle module positioned in the entryinduction station in Block S112, and the controller 180 can then adjustthe height of the upper induction head of the entry induction station toactively compress the food product to a target thickness, as shown inFIG. 7. By compressing the upper plate onto the food product, the system100 can: ensure sufficient contact between the upper plate and the foodproduct to heat or cook the food product within the cook cycle; andcontrol a thickness of the food product, which may affect the finaldoneness level of the food product for a given heat flux during a cookcycle (e.g., a thicker hamburger patty may be less done than a thinnerhamburger patty given identical cook cycles). In one implementation, thesystem 100 includes a single compression actuator 128 coupled to theentry upper induction head, and the controller 180 can calculate atarget thickness for a hamburger patty loaded in a griddle modulepositioned therein based on the doneness level specified for thehamburger patty and then drive the entry induction station downward tocompress the food product to this target thickness. In thisimplementation, the system 100 can exclude compression actuators 128 atother induction stations such that the upper plate of the griddle modulecompresses the food product due to its own weight when positioned insubsequent induction stations in the system 100, and the controller 180can thus accommodate for a number of induction stations in the system100, a weight of the upper plate and upper plate receptacle, and thesize (e.g., the weight) of the hamburger patty when calculating thetarget thickness of the hamburger patty in the entry induction station.Alternatively, the system 100 can include a compression actuator 128 atthe exit induction station, and the controller 180 can implement similarmethods and techniques to calculate a final target thickness of thehamburger patty to finish cooking the hamburger patty and can drive thecompression actuator 128 in the exit induction station to acorresponding vertical position before the hamburger patty is releasedin Block S162. Yet alternatively, the system 100 can include compressionactuators 128 at multiple induction stations, and the controller 180 canactively set the positions of each of these compression actuators 128throughout a cook cycle in order to achieve a target thickness and/orspecified doneness of a food product upon conclusion of a cook cycle.

In another implementation, the compression actuator 128 includes anelectric motor or a pneumatic cylinder that adjusts a vertical positionof a lower stop that defines a lowest available position of an upperplate relative to its corresponding lower plate. For example, the hubcan include a lower stop configured to set a lower travel limit of anupper plate receptacle, and the compression actuator 128 can be mountedor coupled to the hub and can directly adjust the vertical position ofthe lower stop. Similarly, the upper plate receptacle can include a skid116 that vertically couples the upper plate receptacle to an upperinduction head above, the base can include a lower stop configured toset a lower travel limit of an upper induction head, and the compressionactuator 128 can be distinct from the elevation actuator 127 and can beconfigured to adjust the vertical position of this lower stop to set avertical position of the upper induction head during an intra-stationperiod.

In this variation, the controller 180 can also control the height of anupper plate of a griddle module (e.g., by controlling the position of acorresponding compression actuator 128 and/or a position of thecorresponding upper induction head) based on a doneness specificationfor a food product loaded into the griddle module. In one example, for ahamburger patty assigned a ‘well-done’ specification, the controller 180can trigger the compression actuator 128 to drive the upper plate towardthe lower plate of the griddle module to reduce the offset betweenopposing cooking surfaces of the upper and lower plates, therebycompressing the hamburger patty (or enabling the upper plate to lowertoward the lower plate to compress the hamburger patty), reducing thethermal distance between the center of the patty and the upper and lowerplates, and yielding a higher center temperature in the hamburger pattyfor a given cook time. In this example, for a patty assigned a ‘rare’specification, the controller 180 can trigger the compression actuator128 to drive the upper plate of the griddle module away from the lowerplate to increase the offset distance between the opposing cookingsurfaces of the upper and lower plates, thereby yielding a thickerpatty, a greater thermal distance between the center of the patty and anadjacent plate, and yielding a lower center temperature for a given cooktime. The controller 180 can thus actively position the upper plate of agriddle module or actively set a compression limit for a griddle modulethroughout a cook cycle in order to achieve a doneness level specifiedfor a food product loaded into the griddle module.

Alternatively, a griddle module can include a mechanical or gas spring115 arranged between the hub and an upper plate receptacle andconfigured to resist compression of a patty in the griddle module due tothe weight of the upper plate and the upper plate receptacle assembly,as shown in FIG. 5. In particular, in this implementation, the spring115 can be selected for a spring 115 constant (at a typical operatingtemperature when the system 100 is in operation) to achieve a targetcompression of a patty in the griddle module by the weight of the upperplate and the upper plate receptacle. For example, the system 100 caninclude a spring 115 arranged between an upper plate and the hub andconfigured to counter compression of the first food product between theupper plate and the lower plate due to a weight of the upper plate; anda stop coupled to the hub and defining a lower position limit of theupper plate relative to the lower plate.

As a person skilled in the art will recognize from the previous detaileddescription and from the figures and claims, modifications and changescan be made to the embodiments of the invention without departing fromthe scope of this invention as defined in the following claims.

We claim:
 1. A system for cooking a food product comprises: a firstgriddle module comprising a lower plate configured to receive a firstfood product and an upper plate arranged over the lower plate andconfigured to contact the first food product; a set of inductionstations comprising an entry induction station and an exit inductionstation, each induction station in the set of induction stationscomprising a lower coil configured to inductively couple to the lowerplate when the first griddle module is arranged in the induction stationand an upper coil configured to inductively couple to the upper platewhen the first griddle module is arranged in the induction station; abase comprising a barrier, supporting the lower coils of the set ofinduction stations on a first side of the barrier, and supporting theupper coils of the set of induction stations on a second side of thebarrier opposite the lower coils of the set of induction stations,wherein, for each induction station of the set of induction stations,the upper coil of the induction station is aligned with the lower coilof the induction station; a hub configured to support the lower plateand the upper plate of the first griddle module between the barrier andthe upper coils of the set of induction stations, the lower plate offsetabove the barrier and the upper plate offset below the upper coils ofthe set of induction stations, and configured to sequentially positionthe first griddle module at each of the set of induction stations fromthe entry induction station to the exit induction station; and acontroller configured to drive the lower coils and the upper coils ofthe set of induction stations based on a position of the first griddlemodule relative to the set of induction stations to heat the first foodproduct between the lower plate and the upper plate.
 2. The system ofclaim 1, wherein: during a first period of time, the hub positions thefirst griddle module between the lower coil and the upper coil of theentry induction station; during a second period of time succeeding thefirst period of time, the hub repositions the first griddle modulebetween the lower coil and the upper coil of a second induction stationof the set of induction stations adjacent the entry induction station;and between the first period of time and the second period of time, thecontroller deactivates the lower coils and the upper coils of the entryinduction station and the second induction station.
 3. The system ofclaim 1, wherein: the set of induction stations are patterned radiallyabout an axial center of the hub; the system further comprises a secondgriddle module; at a first time, the hub (i) positions the first griddlemodule in alignment with the entry induction station to receive thefirst food product and (ii) positions the second griddle module inalignment with the exit induction station to release a second foodproduct; and at a second time succeeding the first time, the hub (i)positions the first griddle module in alignment with a second inductionstation of the set of induction stations adjacent the entry inductionstation to heat the first food product and (ii) positions the secondgriddle module in alignment with the entry induction station to receivea third food product.
 4. The system of claim 1, further comprising aretrieval system comprising a paddle and a retrieval actuator configuredto, when the first griddle module is positioned in the exit inductionstation, advance the paddle across the lower plate of the first griddlemodule to collect a patty from the lower plate.
 5. The system of claim4, wherein: the paddle defines a tip initially declined downward at afirst angle below horizontal; the retrieval actuator drives the tip ofthe paddle downward against a top surface of the lower plate of thefirst griddle module positioned in the exit induction station until thetip of the paddle is declined downward at a second angle less than thefirst angle below horizontal; and the retrieval actuator pivots thepaddle horizontally to move the first food product from the lower plateonto the paddle.
 6. The system of claim 5, wherein: the retrieval systemfurther comprises a ledge arranged over a dispense position; and theretrieval actuator is configured to draw the paddle along the ledge todrive the first food product off of the paddle and into a containerdisposed below the paddle.
 7. The system of claim 1, wherein: the lowerplate comprises a ferrous substrate and a non-stick coating; the upperplate comprises a ferrous substrate and a non-stick coating; the hubcomprises a lower plate receptacle configured to transiently receive thelower plate; and the upper plate comprises an upper plate receptacleconfigured to transiently engage the hub and to coaxially align with theupper plate and with the lower plate.
 8. The system of claim 7, wherein:the hub comprises a sensor lead receptacle; the upper plate furthercomprises a temperature sensor proximal an axial center of the upperplate and a sensor lead extending laterally from the temperature sensor,the sensor lead is transiently coupled to the sensor lead receptacle ofthe hub; the hub transmits a value from the temperature sensor to thecontroller; and the controller modulates power outputs of the uppercoils in the set of induction stations based on a position of the firstgriddle module within the set of induction stations, a temperature valuereceived from the temperature sensor, and a doneness value selected forthe first food product arranged in the first griddle module.
 9. Thesystem of claim 1, wherein: the hub comprises a linear slide coupled tothe upper plate of the first griddle module, and the upper plate of thefirst griddle module is configured to translate vertically along thelinear slide relative to the lower plate of the first griddle module.10. The system of claim 9, further comprising: a spring arranged betweenthe upper plate and the hub, wherein the spring counters compression ofthe first food product between the upper plate and the lower plate dueto a weight of the upper plate; and a stop coupled to the hub, whereinthe stop defines a lower position limit of the upper plate relative tothe lower plate.
 11. The system of claim 9, further comprising: acompression actuator, wherein the controller calculates a targetcompression distance for the first food product based on a donenessvalue selected for the first food product, and wherein the controllerdrives the compression actuator to a target vertical positioncorresponding to the target compression distance for the first foodproduct.
 12. The system of claim 1, further comprising an elevationactuator proximal the entry induction station and configured to separatethe upper plate of the first griddle module from the lower plate of thefirst griddle module to receive the first food product on the lowerplate.
 13. The system of claim 1, further comprising: a trough extendingalong an edge of the barrier; a collection canister; a conduit extendingfrom a bottom of the trough to the collection canister; a heatingelement arranged on the conduit; and a wiper mounted to the hub,extending across a surface of the barrier, and configured to drive foodwaste deposited onto the barrier toward the trough during rotation ofthe hub.
 14. The system of claim 1, wherein a space is disposed betweenthe lower coils of the set of induction stations and the lower plate ofthe first griddle module in a direction parallel to an axis about whichthe first griddle module rotates relative to the lower coils.